Wire Harness, Cable & Electromechanical Assembly worked example

Electromechanical Assembly Cost at 66% first-pass yield: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop first-pass yield to 66%, then walk the calculation through step by step. Estimate the build cost of electromechanical assemblies by combining touch labor, components, yield and line setup into one quoted figure.

The inputs for this scenario

  • Assemblies Built: 250 units (held at the documented default)
  • Labor + Component Rate: 85 $/unit (held at the documented default)
  • First-Pass Yield: 66 % (the input this scenario stresses; the baseline uses 92)
  • Tooling & Fixture Setup: 1,800 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = assemblies x (labor + component rate) x first-pass yield% + tooling setup.
  • Total electromechanical assembly cost works out to 15,825 $ at these inputs, and this is the headline figure for the scenario.
  • Electromechanical assembly cost per unit works out to 63.3 $ / piece at these inputs.
  • Variable electromechanical assembly cost works out to 14,025 $ at these inputs.
  • Fixed electromechanical assembly cost adder works out to 1,800 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass yield sits at 92% and the headline result is 21,350 $, this scenario comes in 25.88% below the baseline at 15,825 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to first-pass yield, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. The single blended labor+component rate hides which of the two is driving cost, so it will not tell you whether a price increase came from copper, connectors, or slower cycle times.

Results at a glance

  • Total electromechanical assembly cost: 15,825 $ (headline result)
  • Electromechanical assembly cost per unit: 63.3 $ / piece
  • Variable electromechanical assembly cost: 14,025 $
  • Fixed electromechanical assembly cost adder: 1,800 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Electromechanical Assembly Cost calculator, set first-pass yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.